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Ingersoll-Rand HL1200 - User Manual

Ingersoll-Rand HL1200
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HL SERIES DESICCANT DRYER
MODELS 90-5000
OPERATORS MANUAL
C.C.N. : 80442833 en
DATE : APRIL 2010
REV. : D
Ensure that the operator reads and understands the decals
and consults the manuals before maintenance or operation.
Ensure that the Operation and Maintenance manual is not
removed permanently from the machine.
Ensure that maintenance personnel are adequately trained,
competent and have read the Maintenance Manuals.
PRINT LANGUAGE
ENGLISH
FRENCH
PORTUGUESES
SPANISH

Table of Contents

Questions and Answers

  • C
    Cathy KirkAug 14, 2025
    What to do if Ingersoll-Rand Dryer has elevated dew point?
    • P
      Patrick BautistaAug 14, 2025
      If your Ingersoll-Rand Dryer has an elevated dew point, several factors could be the cause. First, check the purge flow settings to ensure they are sufficient. Also, inspect the purge piping for any obstructions and clean the purge piping and muffler. Verify that the inlet air pressure meets the design conditions and check the system for leaks. Ensure the flow rate is within the design specifications and address any increased demand. If the inlet temperature exceeds the design condition (120°F), inspect and service the aftercooler. Also, check the air/moisture separator and pre-filter for entrained water and replace the dryer desiccant if needed. Finally, if the desiccant is contaminated by oil, install a suitable pre-filter and replace the dryer desiccant.
  • N
    Nicholas SmithAug 18, 2025
    Why Ingersoll-Rand Dryer fails to shift?
    • A
      Amy BuchananAug 18, 2025
      If your Ingersoll-Rand Dryer fails to shift, it could be due to several reasons. First, check the power input to ensure there is power. Next, inspect the no-loss drain valve for any defects. Also, check the pilot air line and ensure that the control air line filter is clean. Finally, examine the pilot-operated diaphragm valve seals and replace them if necessary.
  • M
    Mrs. Rebekah PerezAug 21, 2025
    What to do if Ingersoll-Rand Dryer has excessive pressure drop?
    • T
      Tom GoodwinAug 21, 2025
      If your Ingersoll-Rand Dryer experiences an excessive pressure drop, it could be due to excessive flowrate, so check the flow rate and cause for increased air demand. It could also be caused by the inlet pressure being below the design condition, in which case you should check the pressure source.
  • M
    moniquemolinaAug 25, 2025
    What to do if my Ingersoll-Rand Dryer fails to pressurize?
    • C
      Courtney AustinAug 25, 2025
      If your Ingersoll-Rand Dryer fails to pressurize, check that the repressurization circuit is sending a control signal to the purge valve. Also, inspect the purge valve and its no-loss drain valve.
  • A
    adamkrauseAug 28, 2025
    What to do if Ingersoll-Rand Dryer depressurizes too rapidly?
    • H
      Hayley GonzalezAug 28, 2025
      If your Ingersoll-Rand Dryer depressurizes too rapidly, it may be because the purge valve does not close, causing the dryer to repressurize through the inlet valve. Check the purge valve and its no-loss drain valve.
  • D
    Desiree WatkinsAug 31, 2025
    What to do if the Blue Moisture Indicator (BMI) indicates high moisture level in Ingersoll-Rand Dryer?
    • E
      Elizabeth NguyenAug 31, 2025
      If the Blue Moisture Indicator (BMI) in your Ingersoll-Rand Dryer indicates a high moisture level, it could be due to an elevated dew point. Refer to the corrective actions for 'Elevated Dew Point'. Also, if the BMI is wet, it may take a week or more of continuous use for it to switch back to its blue (dry) state, depending on the degree of saturation of the desiccant.
  • J
    James SantosSep 4, 2025
    How to fix Ingersoll-Rand Dryer that fails to purge?
    • R
      Robert WeberSep 4, 2025
      If your Ingersoll-Rand Dryer fails to purge, it may be because the purge valve does not open or is stuck in the closed position. Check the purge valve and its no-loss drain valve, and repair or replace them if necessary. Also, check that the repressurization circuit is sending a control signal.
  • E
    Edward CookSep 7, 2025
    What causes excessive back pressure in regenerating tower of Ingersoll-Rand Dryer?
    • M
      Michael GarrettSep 7, 2025
      Excessive back pressure in the regenerating tower of your Ingersoll-Rand Dryer (above 5 psig) could be due to a dirty purge muffler that does not pass air; replace it. It may also be caused by the purge muffler passing too much air because air is leaking across the valve; check the inlet valve and outlet check valves, and verify the inlet valve is closed to the purging tower (0 psig tower).
  • J
    jennifergoodmanSep 12, 2025
    What causes excessively high pressure at the purge gauge on the right tower of Ingersoll-Rand Dryer?
    • H
      Hannah StephensSep 12, 2025
      If there is excessively high pressure at the purge gauge on the right tower of your Ingersoll-Rand Dryer, it could be due to improper calibration. Reset it when the right tower is online.

Summary

General Safety and Operation Precautions

Personnel Qualification and Training

Only qualified personnel should perform adjustments, maintenance, or repairs.

Pre-Operation and Maintenance Safety

Read instructions, disconnect power, and follow all safety warnings before servicing.

Hazard Warnings: Voltage and Pressure

Caution: Hazardous voltage inside. Depressurize before disassembly. Follow all notices.

Principles of Desiccant Dryer Operation

Microprocessor Controller Functions

Alarm System and Alarm List Access

Understanding dryer alarms and accessing the stored alarm history.

Installation and Initial Start-up Procedures

Application Requirements and Checks

Verify design and installation requirements for optimal dryer performance.

Locating, Mounting, and Piping

Initial Start-up and Shut-down

Step-by-step guide for powering up, operating, and safely shutting down the dryer.

Filtration and Optional Transmitter Installation

Importance of Filtration Systems

Mandatory filtration requirements for dryer protection and warranty.

Electrical Connections and System Checks

Electrical Connection Guidelines

Ensure correct wiring, grounding, and fusing according to diagrams and codes.

Technician Mode Settings and Parameters

Entering and Understanding Technician Mode

Energy Management System (EMS) Configuration

EMS Description and Activation

Minimizing purge air loss by using dew point sensor data for control.

Setting EMS and Dew Point Adjuster

Restart Mode and Purge Flow Adjustment

Compressor Interlock and High Dew Point Alarm

Compressor Interlock Operation

Aligning dryer purge with compressor loading status for energy savings.

High Dew Point Alarm Setup

Configuring the alarm to notify of failure to meet specified pressure dew points.

Scheduled Maintenance and System Checks

Daily, Semi-Annual, and Annual Checks

Routine checks for pressure, flow, indicators, filters, and desiccant.

Pre-filter and Post-filter Servicing

Procedures for maintaining filter elements to protect desiccant and air quality.

Muffler, Valve, and Check Valve Maintenance

Desiccant Changeout Procedure

Step-by-step instructions for safely replacing the desiccant material.

Troubleshooting Common Dryer Problems

Troubleshooting Elevated Dew Point

Diagnosing and resolving issues causing high dew points in the output air.

Addressing Moisture Indicator and Pressure Drop

Resolving BMI indications and excessive pressure drop across the dryer.

Diagnosing Failure to Shift and Pressurization

Troubleshooting switching failures, valve malfunctions, and lack of pressurization.

Resolving Purge and Back Pressure Issues

Correcting problems related to purge valves, mufflers, and excessive back pressure.

Wiring Diagram for Dryer Control

Flow Diagram and Legend

Replacement Parts Identification and Ordering

Parts for HL90-HL250 Models

Parts for HL300-HL800 Models

Parts for HL1000-HL2100 Models

Parts for HL2700-HL5000 Models

Ingersoll-Rand HL1200 Specifications

General IconGeneral
Airflow Capacity1200 CFM
Motor Power15 HP
Operating Pressure100 PSIG
TypeRefrigerated
Maximum Operating Pressure150 PSIG
Inlet Temperature120 °F
Pressure Dew Point38°F
Ambient Temperature Range35°F to 100°F

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